The Need
A leading FMCG manufacturer was looking for a solution that will improve efficiency in their production Line change over process for their labeling section. Current manual process is time intensive and hence inefficient with heavy dependency on technician’s skill and performance.
Impacts Delivered
- Over 80% productivity improvements in the change over process.
- 40% lower TCO by leveraging Gadgeon IIoT solution platform – Delpheon.
- Data-driven improvement initiatives for making the change-over process more efficient
Our Solution
- Solution was realized by leveraging the Delpheon platform of Gadgeon.
- Retrofitted the existing manual readout (Scale) with a digital scale for the Labeler.
- The digital measurements will flow to an edge gateway via an aggregator.
- The received data is processed & compared against reference values for each bottle type. This is used to adjust the positions in the scale and will display the readout in local HMI for the Technician.
- Data analytics with KPIs and dashboards were created.
- Gadgeon leveraged its proprietary Delpheon platform for data aggregation and dashboarding.
- Gadgeon worked with process team to identify the points which can be digitized to help the technicians.
- Laser sensors were installed to measure the set-up point and displayed the same using intuitive dashboards.
- The classification of the deviation were done (Green & Red ) to display the severity and it enabled the technician to do immediate corrective action
Sensors
- We have used industrial grade laser measurement sensor with an accuracy of ±0.1mm to measure equipment positions.
Aggregator
- The Aggregator will collect all the analog/digital output from the sensors and will convert to Modbus TCP protocol for Edge gateway.
- There may be more than one Aggregator depending on the location.
Edge Gateway
- The edge Gateway is a Linux based gateway software running on an Off the shelf hardware.
- It collects data from the sensors through the Modbus interface and stores in a local DB.
- The system will compare the received values against reference values based on the bottle type and the results will be displayed on the screen.
- The screen can be accessed using any standard browser from any of the devices in the factory network.
Tools & Technologies
- Data collection and process logics – Delpheon IoT Platform
- Data analytics and Dashboarding using Delpheon Low-code platform.
- Real-time notification – SMS / Email
